Integrally formed B-pillar and belt-line window molding

ABSTRACT

A combination B-pillar molding and belt-line window molding for a motor vehicle door, and method for manufacturing the same. The molding comprises a main body including a window sealing structure and a mounting structure. The sealing structure is formed from a resilient material constructed and arranged to seal a belt-line gap between a motor vehicle door and a motor vehicle window. The mounting structure is constructed and arranged to mount the main body on a belt-line region of the motor vehicle door. The molding further includes a metal cover member having an elongate first portion with a channel configuration. The channel configuration of the first portion is flexible outwardly to receive a portion of the main body and flexible inwardly to grippingly engage the portion of the main body in secured relation. The metal cover member has an elongate second portion integrally formed with the first portion and extends laterally from the first portion. The second portion is constructed and arranged to extend generally vertically and in overlying relation with respect to a B-pillar of the motor vehicle door.

This application claims priority from provisional application Ser. No.60/021,409, filed Jul. 9, 1996.

BACKGROUND OF THE INVENTION

The present invention relates to window moldings, and in particular,window moldings for a motor vehicle which are constructed and arrangedto seal the interface between an automobile window glass and an adjacentbody structure.

Conventionally, automobiles are provided with elongate window moldingswhich are constructed and arranged to form a seal between window glassand the surrounding or adjacent body structure on which the glass ismounted. Typically, the window molding is fixed to the vehicle bodystructure and provides a sealing engagement with the periphery of thewindow glass to prevent water and other environmental elements frompassing between the body structure and the window glass.

Because window moldings have a main body which is usually notparticularly aesthetically appealing, the main body is covered with amore appealing cover member. The cover member may be painted, anodized,chrome-plated, or otherwise treated.

Conventionally, the cover member has been secured to the main bodyportion of the window molding in a variety of different methods. In oneconventional method, the cover member is extruded directly onto the mainbody portion generally towards the end of the manufacturing process.Typically, the body portion itself, which normally comprises a rubber orresilient material, and in some cases, an accompanying rigid structureor rigid insert, is itself extruded. By forming the cover member as anextrusion over the extruded main body portion, the manufacturer mustdesignate the particular configuration, construction, and appearance ofthe cover member at the same time at which the main body portion isbeing completed. This method renders it rather impractical for themanufacturer to manufacture a large number of main body portions, andthen later decide the type, shape, etc. of cover member to be applied tothe main body portion. As a result, manufacturing flexibility isimpaired, and the cost-savings associated with manufacturing a largenumber of body portions at one time is not realized.

In an alternate manufacturing process, the body portion is extruded suchthat it is configured to have a pair of longitudinal grooves which areconstructed and arranged to receive the edges of a channel-like covermember by sliding such edges along the grooves in a longitudinalfashion. This is a rather laborious and tedious task, especially where adegree of curvature is to be provided in the window molding.

In yet other arrangements, the cover member is secured to the main bodyportion by various types of separate clip-members or attachment-memberswhich form the connecting interface between the cover member and mainbody portion. These clip members are inconvenient in the manufacturingprocess and add to the total cost of the molding. In yet otherarrangements, the molding is glued with an adhesive to the main bodyportion. This adds costs and complexity to the manufacturing process.

It is an object of the present invention to overcome the shortcomingsnoted above. In accordance with this object, the present inventionprovides a method of assembling a belt-line window molding for a motorvehicle door comprising i) a main body including a resilient windowsealing structure constructed and arranged to seal a gap between themotor vehicle door and the motor vehicle window, and a mountingstructure constructed and arranged to mount the window molding on themotor vehicle door, the mounting structure including a rigid portion,and ii) a metal cover member having a channel configuration constructedand arranged to cover a portion of the mounting structure which isadapted to extend in overlying relation to an exterior surface of thedoor. The method comprises forming the main body by extrusion; placingone edge of the metal cover member in an edge receiving recess of themain body; pivoting the metal cover member generally about the one edgeso as to cause an opposite edge of the metal cover member to engage therigid portion of the mounting structure; forcing the opposite edge ofthe metal cover member to move in sliding engagement across the rigidportion; outwardly flexing the channel configuration of the metal covermember as a result of the cover member being forced to move in slidingengagement across the rigid portion; and inwardly flexing the covermember back towards its original configuration and into grippingengagement with the rigid portion to secure the cover member to the mainbody.

It is preferred that the metal cover member be secured to the main bodybefore the window molding is mounted on the motor vehicle. It is alsopreferred that the cover member be treated (e.g., anodized, chromeplated, painted) after the main body is formed by extrusion.

It is a further object of the invention to provide a belt line windowmolding for a motor vehicle comprising a main body including a windowsealing structure and a mounting structure, the sealing structure formedfrom a resilient material constructed and arranged to seal a gap betweena motor vehicle door and a motor vehicle window, and the mountingstructure constructed and arranged to mount the window molding on themotor vehicle door, the mounting structure including a rigid portionhaving a ridge formed thereon; a metal cover member having a channelconfiguration including a pair of opposite edges, the main body havingan edge receiving recess being constructed and arranged to enable oneedge of the edges to be received therein; the edge receiving recessbeing cooperable with the one edge to enable the cover member to bepivoted generally about the one edge to enable an opposite edge of theedges to engage the rigid portion of the mounting structure and rideupward and over the ridge formed on the rigid portion, the metal covermember flexing outwardly as it rides upward the ridge, and then flexinginwardly after it rides over the ridge, and the metal cover member thusbeing retained in secure engagement with the main body.

A further object of the present invention is to provide a combinationbelt-line molding and B-pillar molding for a motor vehicle door whichachieves the desired flexibility noted above. In accordance with thisobject, the present invention provides a combination B-pillar moldingand belt-line window molding for a motor vehicle door, and method formanufacturing the same. The molding comprises a main body including awindow sealing structure and a mounting structure. The sealing structureis formed from a resilient material constructed and arranged to seal abelt-line gap between a motor vehicle door and a motor vehicle window.The mounting structure is constructed and arranged to mount the mainbody on a belt-line region of the motor vehicle door. The moldingfurther includes a metal cover member having an elongate first portionwith a channel configuration. The channel configuration of the firstportion is flexible outwardly to receive a portion of the main body andflexible inwardly to grippingly engage the portion of the main body insecured relation. The metal cover member has an elongate second portionintegrally formed with the first portion and extends laterally from thefirst portion. The second portion is constructed and arranged to extendgenerally vertically and in overlying relation with respect to aB-pillar of the motor vehicle door.

Further objects and advantages of the present invention will beappreciated from the following detailed description, drawings andclaims.

DETAILED DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of a belt-line window molding showninstalled on a vehicle door in accordance with the principles of thepresent invention;

FIG. 2 is a cross-sectional view taken through the line 2—2 in FIG. 1;

FIG. 3 is a cross-sectional view of the cover trim member in the processof being installed on the belt-line window molding in accordance withprinciples of the present invention;

FIG. 4 is a perspective of a combination belt-line window molding andB-pillar molding in accordance with a second embodiment of the presentinvention, shown installed on a vehicle door;

FIG. 5 is a cross sectional view of the taken through the line 4—4 inFIG. 4 of the B-pillar portion of the molding of the second embodimentof the present invention.

Shown generally in FIG. 1 is a belt-line window molding 10 manufacturedin accordance with the principles of the present invention. The windowmolding 10 is shown mounted on the upper portion of a motor vehicle doorbody 12, illustrated in broken-line configuration. In particular, thewindow molding 10 is mounted longitudinally along the belt-line of thevehicle door at the portion at which the outer door panel 14 and innerdoor panel 16 are joined. In the preferred embodiment, the windowmolding 10 generally includes a main body 11 and a cover trim member 60as will be more fully described.

FIG. 2 is a cross-sectional view taken through the line 2—2 in FIG. 1.As shown, the main body 11 includes a seal member or seal structure 30,and a door mounting structure 50. The door mounting structure has rigidinterior support structure 18, preferably made of aluminum. Steel,hardened plastic, or other rigid material can also be used. The supportstructure 18 includes a substantially flat plate portion 20, which isconstructed and arranged to extend downwardly between the door body 12and the vehicle window, which window is represented generally inbroken-line configuration by reference numeral 22. The support structure18 further includes an upper bent portion 24 extending from the plateportion 20 and is constructed and arranged to bend over the jointbetween the inner door panel 16 and outer door panel 14. The supportstructure 18 then extends downwardly from the bent portion 24 to flangeportion 26 thereof. In essence, the support structure 18 has aninverted-J cross-sectional configuration.

Support structure 18 is imbedded along its entire extent within the sealor member 30 and the door mounting structure 50, as shown. The sealmember 30 and door mounting structure 50 together form the main body 11of the window molding 10. The upper part of plate portion 20 on thewindow facing side thereof, is covered by the seal member 30. The sealmember 30 is preferably made from a flexible, resilient material, suchas Sumprene, or the like. Seal member 30 preferably includes an upperseal portion 32 and a lower seal portion 34, which portions extendgenerally between the door body 12 and the window 22 to prevent externalelements, such as rainwater, from entering between the door body 12 andwindow 22. The underside of the upper seal portion 32 and the undersideof the lower seal portion 34 are provided with conventional dorrie flockmaterial, indicated by reference numeral 36. The upper seal portion 32and the lower seal portion 34 are constructed and arranged to flex andapply a resilient force against the window 22, as can be appreciatedfrom the broken-line illustration of the upper seal portion 32 and lowerseal portion 34. In particular, the upper seal portion 32 and the lowerseal portion 34 force the dorrie flock material against the window, withthe dorrie flock material providing a sliding friction seal, whichpermits sliding movement of the window, but prevents rainwater fromseeping between the window 22 and door body 12.

The mounting structure 50 covers the rest of the support structure 18which is not covered by seal member 30, and is preferably made from arigid PVC material. The mounting structure 50 meets the seal member 30at joints 52, 53 therebetween and is constructed and arranged to mountthe entire molding 10 on the door body 12. The mounting structure 50includes a flange portion 40, which surrounds the flange portion 26 ofthe support structure 18. The flange portion 40 includes an enlarged endportion 42, which is constructed and arranged to engage the exteriorsurface of the outer door panel 14. The portion of the mountingstructure 50 adjacent the plate portion 20 and which faces away from thewindow 22, includes flanges 54 and 55, which are constructed andarranged to engage the exterior surface of the inner door panel 16. Themounting structure 50 further includes a lower projection 56, which isadapted to extend within an opening in the inner door panel 16. Theflanges 54, 55, projection 56, and end portion 42 serve to mount themolding 10 on the door 12. In particular, in the configuration shown inFIG. 2, the flange portion 26 and plate portion 20 of the supportstructure 18 are moved slightly outwardly away from one another byslight outward flexing of bent portion 24 against the natureconfiguration thereof when the entire window molding 10 is slipped overthe upper part of the door body 12. This causes the end portion 42 ofthe flange portion 40 and opposing flanges 54, 55 to apply a resilientforce against the exterior surface of the door body 12 to thus pinch theupper portion of the door body 12 therebetween. When the molding is slidonto the door, the projection 56 rides down the upper portion of theinner door panel 16 until it reaches the door opening, at which point isresiliently “snapped” in place within the opening to secure the molding10 to the door body 12. As can be appreciated from FIG. 1, theprojection 56 does not extend the entire length of the molding, asneither does the opening in the inner panel 16 within which theprojection 56 fits, as will be appreciated by those skilled in the art.

The mounting structure 50 is also provided with a dorrie flock material36 at a lower portion thereof facing window 22 in the event that thisportion is to engage the window 22, although this is not the case withthe preferred embodiment shown. The flange portion 40 also includes abottom ridge portion 44, which defines the lowermost extremity of theflange portion 40 when installed.

Preferably, the seal member 30, the mounting structure 50, the dorrieflocks 36, and the support structure 18 are extruded together in anin-line extrusion process. After these elements have been manufactured,a cover trim member 60 is snapped in place to cover the flange portion40 of the mounting structure 50 for aesthetic and protective purposes.

The installation of the cover trim member 60 can be appreciated morefully from FIG. 3. Preferably, the cover trim member is secured to therest of the molding as a final assembly step of manufacturing themolding before the molding 10 is installed on the door, although it iscontemplated that it is possible to provide an arrangement wherein thecover trim member 60 is installed after the rest of the molding isinstalled on the door. As shown, an opening 62 is provided generally atthe upper joint 53 between the seal member 30 and mounting structure 50.The cover trim member 60 has a generally C-shaped cross-sectionalconfiguration. An upper lip 64 of this C-shaped configuration isconstructed and arranged to be received within the opening 62. In themethod of installation, the cover trim member 60 is pivoted about thisupper lip 64 (in a counter-clockwise direction in FIG. 3) until a lowerbent lip 66 engages the lower part of the flange portion 40. Moreparticularly, the lower bent lip 66 of the cover trim member 60 engagesthe bottom ridge portion 44, and is forced to ride over the ridgeportion 44 to snap-in place on the other side of the ridge portion 44,thus securing the cover trim member 60 in place. The movement of thecover trim member 60 over the ridge portion 44 may be effected by aslight outward flexing of the C-shaped cross-section of the cover trimmember 60 and/or a slight inward compression or flexure of the flangeportions 26, 40 towards the plate portion 20.

Because the cover trim member 60 is formed separately from the rest ofthe window molding 10, significant flexibility with respect to theparticular requirements of the cover trim member 60 is accommodated.More particularly, for different applications, the cover trim member canbe made of one of many different types of materials, such as aluminum orsteel. Preferably, the trim member 60 is formed from sheet metal in aconventional roll forming operation. In addition, it may be desirable tohave the cover trim member 60 anodized or chrome-plated. Furthermore, itmay be desirable to have the cover trim member painted or otherwisecolored based upon the color of the vehicle body or other factors.Because the cover trim member 60 can be installed subsequent to the restof the window molding, particular specifications for the cover trimmember 60 need not be specified when the rest of the molding ismanufactured.

FIG. 4 is a perspective of a combination belt-line window molding andB-pillar molding, generally indicated at 100, in accordance with asecond embodiment of the present invention. The molding 100 is showninstalled on a vehicle door, indicated at 102.

The molding 100 has a main body 104, which is identical in all respectswith the main body 11 of the first embodiment. As shown, as in the firstembodiment, the main body has an elongate resilient sealing structure106, which seals the gap between the door 102 and the vehicle window108.

The embodiment shown in FIG. 4 differs from the first embodiment in thatthe molding 100 has a cover member 110 which not only covers a portionof the main body, but also has a lateral extension that covers the doorB-pillar 116. More particularly, the cover member has an elongate firstportion 112 which extends generally horizontally in overlying relationwith the main body 104, and also has a second portion 114 which extendsgenerally vertically in overlying relation with respect to the doorB-pillar 116. The first portion 112 is integrally formed with the secondportion 114 from a sheet metal stamping. The second portion 114 is fixedto the door B-pillar 116 preferably by riveting, bolting, welding, or inany other conventional fashion. The second portion 114 is preferablyfixed at its inner surface so as to mask its connection with theB-pillar 116 for aesthetic purposes.

As in the first embodiment, the cover member 110 is preferably made froma metal material, and most preferably from aluminum. Unlike the firstembodiment, however, the cover member 110 is formed by stamping, ratherthan roll forming, to accommodate its L-shaped general configuration asshown, and also to accommodate the different cross-sectional shapes ofthe first portion 112 and the second portion 114. More particularly, thefirst portion 112 has a generally rounded “C-shaped” cross-sectionalconfiguration (as is the case with the cover member 60 in the firstembodiment), while the second portion 114 has a more squared “C-shaped”configuration, as can be appreciated from FIG. 5, which is a crosssectional view of the taken through the line 4—4 in FIG. 4. It can beappreciated that the squared “C-shaped” cross sectional configuration ofsecond portion 114 includes a pinched portion 118 forming a flange at alower left hand corner of the sqared C-shaped configuration as shown.

In recent years the motor vehicle manufacturing business has recognizedthe great costs involved in maintaining large inventories of parts foruse on the assembly line. Particularly with respect to parts supplied byother parts supplying entities, original equipment manufacturers arereluctant to assume the costs of the large inventories and are passingon to the part maker the costs involved in supplying sufficient parts tokeep the assembly line running. Window moldings often need to match theexterior finish of their vehicle. Modem motor vehicle stylingrequirements are such that there can be 17 or more different colorexterior finishes that must be matched by the part maker of the windowmolding for the vehicle. The present invention effectively deals withinventory cost problems in a cost-effective manner.

It thus will be seen that the objects of this invention have been fullyand effectively accomplished. It will be understood, however, that theforegoing preferred specific embodiments have been shown and describedfor the purpose of this invention and is subject to change withoutdeparture from such principles. Therefore, this invention includes allmodifications encompassed within the spirit and scope of the followingclaims.

What is claimed is:
 1. A method of assembling and installing acombination B-pillar and belt-line window molding for a motor vehicledoor, said combination molding comprising i) a metal cover member havinga first portion with a pair of edges and a channel configuration, and asecond portion integrally formed with said first portion and extendinglaterally from said first portion, said second portion constructed andarranged to be mounted on the door to extend vertically and in overlyingrelation to a B-pillar of said door, (ii) a main body including anelongate resilient window sealing structure constructed and arranged toextend horizontally to seal a belt-line gap between the motor vehicledoor and a motor vehicle window carried by said door, and a mountingstructure constructed and arranged to mount the main body on a belt-lineregion of the motor vehicle door with a rigid portion of said mountingstructure overlying an exterior surface of said door, said rigid portionhaving sufficient rigidity such that when one of said edges of saidmetal cover member is inserted into said edge receiving recess and thensaid cover member is pivoted generally about said one edge so as toengage an opposite one of said edges of said metal cover member withsaid rigid portion, applying a force to said cover member to move saidopposite edge of said metal cover member in sliding relation across saidrigid portion to outwardly flex said cover member, said methodcomprising: forming said main body by extrusion; placing said one edgeof said first portion of said metal cover member in said edge receivingrecess of said main body; pivoting said metal cover member generallyabout said one edge so as to engage said opposite edge of said firstportion of said metal cover member with said rigid portion of saidmounting structure; applying a force to said cover member to move saidopposite edge of said metal cover member in sliding engagement acrosssaid rigid portion such that said metal cover member outwardly flexes toan extent sufficient to allow said opposite edge to slide over saidrigid portion and such that, after said opposite edge slides over saidrigid portion, said cover member flexes back towards its originalconfiguration and into gripping engagement with said rigid member tosecure said cover member to said main body; and mounting said main bodyand said first portion of said cover member on the belt-line region ofsaid door and said integrally formed second portion of said cover memberin overlying relation with respect to the B-pillar of said door.
 2. Themethod according to claim 1, wherein said rigid portion of said mountingstructure has a ridge portion formed thereon, and wherein applying saidforce to said cover member forces said opposite edge upwards one side ofsaid ridge in sliding engagement with said one side of said ridge, andwherein after said opposite edge slides over said ridge said oppositeedge rides downwards an opposite side of said ridge as said cover memberflexes back towards its original configuration.
 3. The method accordingto claim 1, wherein said window molding is mounted on the motor vehicledoor after said metal cover member is secured to said main body.
 4. Themethod according to claim 3, wherein said mounting structure of saidmain body comprises an exterior portion constructed and arranged to bedisposed exteriorly to an outer door panel, and an interior portionconstructed and arranged to be disposed between an inner door panel andthe motor vehicle window, and wherein said mounting comprises: movingsaid interior portion downwardly between said inner door panel and saidmotor vehicle window while in sliding engagement with a surface of saidinner door panel; moving said exterior portion downwardly over saidouter door panel while in sliding engagement therewith; outwardlyflexing said mounting structure so that said interior portion andexterior portion move away from one another during said movingdownwardly thereof; inwardly flexing said mounting structure towards itsoriginal configuration as a projection of said mounting structure isreceived within an opening in said inner door panel, said projectionco-acting with an edge defining said opening in said inner door panelfor prevent said molding from being pulled off said vehicle door; andfixing said second portion of said cover member to said B-pillar.
 5. Themethod according to claim 3, further comprising treating said covermember after said forming of said main body by extrusion, and beforesaid cover member is secured to said main body, and wherein saidtreating comprises any one selected from a group consisting ofanodizing, chrome plating, and painting.
 6. The method according toclaim 1, further comprising stamping sheet metal to form said covermember.
 7. A method of assembling and installing a combination B-pillarand belt-line window molding for a motor vehicle door, said methodcomprising: providing a metal cover member having a first portion with apair of edges and a channel configuration, and a second portionintegrally formed with said first portion and extending laterally fromsaid first portion, said second portion constructed and arranged to bemounted on the door to extend vertically and in overlying relation to aB-pillar of said door; providing a main body including an elongateresilient window sealing structure constructed and arranged to extendhorizontally to seal a belt-line gap between the motor vehicle door anda motor vehicle window carried by said door, and a mounting structureconstructed and arranged to mount the main body on a belt-line region ofthe motor vehicle door with a rigid portion of said mounting structureoverlying an exterior surface of said door, said rigid portion havingsufficient rigidity such that when one of said edges of said metal covermember is inserted into said edge receiving recess and then said covermember is pivoted generally about said one edge so as to engage anopposite one of said edges of said metal cover member with said rigidportion, applying a force to said cover member to move said oppositeedge of said metal cover member in sliding relation across said rigidportion to outwardly flex said cover member; placing said one edge ofsaid first portion of said metal cover member in said edge receivingrecess of said main body; pivoting said metal cover member generallyabout said one edge so as to engage said opposite edge of said firstportion of said metal cover member with said rigid portion of saidmounting structure; applying a force to said cover member to move saidopposite edge of said metal cover member in sliding engagement acrosssaid rigid portion such that said metal cover member outwardly flexes toan extent sufficient to allow said opposite edge to slide over saidrigid portion and such that, after said opposite edge slides over saidrigid portion, said cover member flexes back towards its originalconfiguration and into gripping engagement with said rigid member tosecure said cover member to said main body; and mounting said main bodyand said first portion of said cover member on the belt-line region ofsaid door and said integrally formed second portion of said cover memberin overlying relation with respect to the B-pillar of said door.
 8. Amethod according to claim 7, wherein said main body is provided byextruding said main body.